Mediated electrochemical oxidation of organic wastes using a Co(III) mediator in a neutral electrolyte

ABSTRACT

An electrochemical cell with a Co(III) mediator and neutral pH anolyte provides efficient destruction of organic and mixed wastes. The organic waste is concentrated in the anolyte reservoir, where the cobalt mediator oxidizes the organics and insoluble radioactive species and is regenerated at the anode until all organics are converted to carbon dioxide and destroyed. The neutral electrolyte is non-corrosive, and thus extends the lifetime of the cell and its components.

The United States Government has rights in this invention pursuant to Contract No. W-7405-ENG48 between the United States Department of Energy and the University of California for the operation of Lawrence Livermore National Laboratory.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a method for remediation of organic and mixed wastes by mediated electrochemical oxidation of the organic components to carbon dioxide using a Co(III) mediator in a neutral electrolyte.

2. Description of Related Art

Destruction of organic waste through conventional methods such as incineration often encounters political or regulatory hurdles, especially when the waste streams contain radionuclides or chlorinated hydrocarbons, or when harmful species such as dioxins or furans are possible by-products. For this reason, attention has focused on low temperature alternatives. Mediated Electrochemical Oxidation (MEO) is an alternative that avoids many of the problems associated with other organic or mixed waste treatment systems.

MEO oxidizes the organic components of waste to carbon dioxide and water while operating at near ambient pressure and temperature (30-70° C.) in an aqueous system. All waste stream components and oxidation products (except evolved gases) are contained in the aqueous environment. The aqueous electrolyte acts as an accumulator for inorganics that were present in the original waste stream and also provides a thermal buffer for the energy released during oxidation of the organics. The generation of secondary waste is minimal as the process needs no additional reagents. The entire process can be shut down by simply turning off the power, avoiding problems such as thermal runaway.

MEO is based upon the oxidation of organics to carbon dioxide through a series of charge transfer steps involving a mediator. This mediator, typically a transition metal in its highest valency state, is generated at the anode of an electrochemical cell and is dispersed throughout the anolyte solution. Upon oxidation of the organic by the mediator, the reduced mediator species is reoxidized at the anode and the cycle repeats until all oxidizable organic material in the cell is depleted.

Several high-valency metal ions have been investigated as mediators, including Ag(II), Ce(IV), and Fe(III). Each of these systems show different rates with respect to organics oxidation, as well as slightly different optimal waste streams. The silver/nitric add based system arguably has been the most successful of the three, yet the Ag(II) mediator suffers from the problem of being depleted when chlorinated organics are treated, since AgCl is highly insoluble. In addition, the economic and environmental costs of silver are significantly higher than for the other metals.

A cobalt based system was developed by Farmer et al. at Lawrence Livermore National Laboratory and is disclosed in U.S. Pat. No. 5,516,972. This system uses a sulfuric acid (H₂ SO₄) electrolyte and has no cell separator. The choice of a Co(III) mediator is advantageous when treating chloro-containing organics because cobalt chloride complexes are generally soluble, so precipitation of chloride salts is avoided. The rate of reaction of Co(III) with water is relatively slow, thus the parasitic reactions of the mediator with water are minimized. In addition, the economic and environmental costs of cobalt as a mediator are smaller than for other metals, particularly silver. Specifically, the RCRA disposal restriction requirements, both at the federal and state level, are less strict for cobalt than for silver.

Yet the Co(III)/(H₂ SO₄) system described in U.S. Pat. No. 5,516,972 has its own drawbacks, which were uncovered upon further study of the system. Although the system has the seemingly attractive feature of no cell separator, the disadvantage of such a system is that the organic waste stream is diluted in the larger, unseparated volume, and more reagents are required to achieve effective concentrations. Furthermore, corrosion of the electrodes was a significant technical problem for this process, as the combination of acidic media, highly oxidizing species, chlorine species, free radicals, and organic fragments drastically shortened the usable lifetime of the electrode materials tested. The sulfuric acid electrolyte solution was identified specifically as a corrosive environment that readily attacks and dissolves the anode. The corrosion of the electrodes is significant not only because it reduces the lifetime of the electrodes, which are typically made of expensive metals, but it causes the electrode material to be released into the waste stream. Waste contaminated with an electrode material such as platinum is hazardous; waste disposal or recovery of the platinum are time-consuming and costly options.

It is the object of the present invention to address the problems inherent in the Ag(II) and Co(III)/(H₂ SO₄) systems and provide a mediated electrochemical oxidation process that efficiently remediates organic and mixed wastes while minimizing the economic and environmental costs of a waste treatment system.

SUMMARY OF THE INVENTION

The present invention is a method for destroying organic-containing wastes by mediated electrochemical oxidation (MEO), whereby the organics are oxidized via a Co(III) mediator (or oxidant) in an electrochemical cell containing a neutral pH electrolyte. The mediator, Co(III), is cleanly recycled in charge transfer steps at the anode in the electrochemical cell. The cell is separated into reservoirs for the anolyte and catholyte, and the organic material is concentrated in the anolyte. The neutral pH electrolyte does not corrode the electrodes, whereas acidic anolyte solutions, particularly sulfuric acid, are severely corrosive and drastically reduce the lifetime of conventional anodes. The solubility of cobalt in a neutral aqueous solution is greater than in an acidic solution, and a higher mediator concentration hastens the destruction of organics. At the cathode, water (and to a lesser extent, protons produced from the oxidation of the organics) may be reduced to form hydrogen gas. If a nitrate salt is used for the electrolyte solution, the nitrate may be reduced at the cathode to nitrite, which may be contacted with oxygen gas in the catholyte to regenerate the nitrate.

The Co(III) mediator in a neutral solution can be used to convert nearly all organics, whether present in hazardous or in mixed waste, to carbon dioxide. Organics that have been treated include ethylene glycol and 1,3-dichloro-2-propanol. In general, liquid and solid organics such as alcohols, aldehydes, ketones, carboxylic adds, and aromatics are treatable using the present method. This invention can also be used to remove the radioactive component of mixed wastes, while simultaneously destroying the organic components. In particular, organic waste containing transuranic oxides may be treated to convert the oxides to a soluble species that can be recovered by separation and precipitation.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows an electrochemical cell arrangement in a single electrode mode and process chemistry according to the present invention.

FIG. 2 shows an electrochemical cell arrangement in a bipolar electrode mode according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is a mediated electrochemical oxidation (MEO) process that is used to treat wastes containing hazardous organics by converting the organic components of the waste to carbon dioxide. The organics are oxidized by a Co(III) mediator in a neutral pH electrolyte. For mixed wastes, the radioactive components, specifically transuranics, are converted to a soluble form and can be recovered if desired or immobilized for disposal.

FIG. 1 shows an illustrative electrochemical cell arrangement (single electrode mode) and process chemistry for the present invention. The electrochemical cell is separated into two reservoirs by a cell separator 10, such as a membrane. One reservoir contains an anode 12 and an anolyte solution, and the other reservoir contains the cathode 14 and catholyte solution. The anode 12 is typically made of, or coated with, a metal such as platinum. Suitable materials for the cathode 14 include niobium, platinum, titanium, nickel, and tantalum. The anode 12 and cathode 14 are driven by a conventional DC power supply 16.

The anolyte and catholyte solutions are neutral (pH˜7), and typically are made from a salt of a highly soluble alkali metal such as sodium or potassium. Nitrate salts (KNO₃, NaNO₃) are preferred because of their high solubility and because nitrate solutions require a lower cathode potential. Other suitable salts include sulfates (K₂ SO₄, Na₂ SO₄) and phosphates (K₃ PO₄, Na₃ PO₄). The neutrality of the electrolyte provides a significant advantage over systems using acidic electrolytes. An acidic anolyte readily corrodes and dissolves the anode, reducing its lifetime and releasing trace metals into the electrolyte that then require special disposal or recovery processes.

The present invention can also be used in a bipolar mode, shown in FIG. 2, which might provide cost advantages in a commercial cell. The cell has a plurality of bipolar electrodes 20 between the outer anode 22 and cathode 24. A membrane 26 between each pair of electrodes separates the cell into a plurality of anolyte flow channels 28 and catholyte flow channels 30. The total cell voltage is the sum of the individual sub-cells.

The organic waste material to be destroyed can be introduced into the anolyte in either a batch mode or a continuous feed mode. In the batch mode, the organic is added directly into the anolyte reservoir at the beginning of a run. In the continuous feed mode, the organic may be pumped using a metering pump through a small tube into the anolyte reservoir.

The Co(III) mediator is generated at the anode of the electrochemical cell and is dispersed throughout the anolyte solution. Cobalt is typically added to the anolyte in the form of a cobalt salt, such as cobalt nitrate or cobalt sulfate, and cobalt ions are then oxidized at the anode to form the mediator, as given in Reaction (1). The concentration of cobalt in the anolyte should not exceed its solubility limit, which is appreciably greater in a neutral aqueous solution than in an acidic solution. ##EQU1##

Co(III) reacts with the organic material to form carbon dioxide, and in the process is reduced to Co(II). Hetero-atoms present in the organic waste are also oxidized and remain in solution until they are removed in a batch electrolyte regeneration process. Reactions (2) and (3) show representative stoichiometric reactions for ethylene glycol and 1,3-dichloro-2-propanol, respectively. The chlorine gas produced in Reaction (3) is removed from the system in a secondary process. ##EQU2##

If the organic waste also contains a radioactive component, such as a transuranic oxide, then the Co(III) mediator converts the oxide into a soluble species that can be separated and recovered in a preferred form. Reaction (4) is a representative stoichiometric reaction for plutonium oxide. ##EQU3##

Upon oxidation of the organic (or transuranic) by the mediator, the reduced species Co(II) is then reoxidized at the anode and the cycle repeats until the desired amount of oxidizable material in the anolyte is depleted. Thus, the mediator is continually replenished. Organic destruction efficiencies of 95-99% have been achieved using this process.

The electrochemical current loop is completed by the cathode reaction, which is typically the reduction of water to hydroxyl ions and hydrogen gas, as given in Reaction (5). If there is an abundance of protons produced during organic oxidation (e.g., Reactions (2) and (3)) that migrate from the anolyte through the cell separator to the catholyte, then protons may be reduced as well, resulting in the irreversible release of hydrogen gas, as given in Reaction (6). ##EQU4##

If a nitrate salt is used for the electrolyte solution (at sufficiently high concentration), then the nitrate ions will be reduced to nitrite, as shown in Reaction (7). ##EQU5##

The nitrite generated may be removed (pumped) directly from the system and the catholyte replenished with a nitrate solution. Alternatively, the reaction-generated nitrite may be converted back to nitrate. Nitrite that is not removed or converted eventually decomposes to form NO_(x) (i.e, NO and NO₂). NO_(x) species that are produced may be removed from the system using scrubbers. The formation of NO_(x) species may be avoided by contacting the nitrite with oxygen gas (O₂), which oxidizes the nitrite and regenerates nitrate, as represented in Reaction (8). ##EQU6##

Since oxygen is only very sparingly soluble in an aqueous solution, a turbo-aerator was developed at Lawrence Livermore National Laboratory which achieves very high efficiencies in a small volume. The turbo-aerator draws the gas and the fluid together, and passes them through a row of stator blades which disperses the gas into very small bubbles. This device is installed in the catholyte flow loop, and the advantages of intimate mixing and the high surface area contribute to efficient reoxidation to nitrate.

The cell separator, typically a membrane, is used in the system to concentrate the organic waste on the anolyte side. In nitrate-based systems, the membrane also prevents any nitrite formed at the cathode from migrating to the anolyte side and being reoxidized at the anode, causing loss of current efficiency. The separator is often a cationic membrane, although a porous polymer or ceramic membrane can also be used. Suitable cell membranes include Zitex A-125, a porous plastic, and Nafion 117.

There is a net accumulation of water in the system due to the addition of organics and to Reaction (7) in nitrate-based systems. The water may be removed from the system using an evaporator in conjunction with a fractionation column. The electrolyte is passed through the evaporator and a small amount is evaporated off, enough to remove the extraneous water. The concentrated electrolyte is then returned to the cell. The column can be designed to produce water which is directly sewerable, while any recovered electrolyte materials are reused.

The MEO process is able to break down the vast majority of organic materials, such as alcohols, alkenes, carboxylic acids, chloro-/amino-/nitro-/phospho- hydrocarbons, aromatics, ketones, aldehydes, and aliphatic chains. However, the functionalities present in the organic molecules play a significant role in the ease of oxidation. In general, the more oxidizable functional groups an organic material has, the more effective MEO will be in destroying the material. At one extreme, alcohol, double bond, and carboxylic acid groups greatly facilitate the oxidation process; at the other extreme, aliphatic hydrocarbons exhibit slow oxidation. Most organics fall somewhere in between, with more --OH groups and fewer C--H or C--C bonds accelerating the oxidation. Typically, slow or insignificant oxidation occurs if no favorable functionalities are present. The only functional group that has exhibited no oxidation is the C--F bond, such as contained in polytetrafluoroethylene (Teflon), polyvinylidenefluoride (Kynar), and fluoroelastomers (Viton). These polymers make excellent materials for construction of MEO systems due to this inert quality.

To improve oxidation efficiency, the surface area of contact between the mediator, Co(III), and organic materials should be maximized. For soluble organics, this is not a problem as the organic is dispersed homogeneously throughout the anolyte. For insoluble or immiscible compounds, this contact issue can be a significant factor. For organic substrates such as benzene, toluene, and dodecane, the organic compound may simply float on the top of the electrolyte solution (or sink to the bottom), and conversion to carbon dioxide is exceedingly slow.

To process otherwise immiscible organics, emulsions can be formed of a mixture of the organic material and water, with a commercial surfactant added. The mixture is sonicated to a milky appearance and slowly fed into the anolyte reservoir of the cell. Using this technique, conversion of immiscibles (e.g., toluene) to carbon dioxide is nearly quantitative. The emulsion may also be fed through an atomizer, which sprays a fine mist of the emulsion into the anolyte reservoir, further enhancing the surface area contact. Different classes of surfactants have been tried to determine their stability in the MEO environment; surfactants based on trialkyl amine oxides are suitable. Solid organic waste can be introduced in a finely powdered form.

The durability of electrode materials has proven to be a serious problem due to the corrosive MEO environment in the cell, especially at the anode. In a sulfuric acid based system, electrode materials such as platinum, which appeared at first to be an effective anode material, were found to suffer significant degradation. Numerous anode materials coated with platinum were tested, and the platinum coating peeled off or otherwise separated from the base metal, leading to attack on the substrate. The shortened lifetime of the electrodes, as well as the leaching of platinum into the anolyte, would be prohibitively expensive in a large scale system.

Consequently, the Co(III)/neutral anolyte system was chosen (in part) to avoid this problem. Although a nitric acid based system does not attack the anodes as readily as the sulfuric acid, a neutral pH system is better yet. The purpose of the present invention is to eliminate the acidic species entirely from the MEO system to reduce corrosion of the cell components.

The materials of cell construction are chosen to withstand the combination of powerful oxidants, organic fragments, free radicals, and chlorine species present in the anolyte. Typical signs of failure or loss of mechanical integrity are swelling, dissolving, fracturing, excessive weight loss or gain, and perforation. As noted above, plastics containing C--F bonds are quite durable; the oxidizing power of the MEO system is not sufficient to break these bonds. The plastics polyvinylidene fluoride (Kynar), polyethylene, ethylenetetrafluoroethylene, and polychlorotrifluoroethylene, and the metals tantalum and niobium, perform satisfactorily. Glass has some value as a construction material, but is limited by its fragile mechanical properties. Teflon (polytetrafluoroethylene) exhibits no evidence of corrosion in any of the parts used in the cell systems, such as tubing and pump gears.

Corrosion resistant materials, e.g., platinum, tantalum and niobium, in the form of metal strips may be used as electrodes, or a metal such as platinum may be clad or otherwise deposited onto less expensive substrates, e.g., stainless steel, copper or nickel. Better performance is obtained with clad materials; electroplated or sputter deposited materials often have small pores or uneven coating thickness. These small defects drastically lower the lifetime of the sputtered or electrodeposited materials, as the anolyte solution seeps through these pores and attacks the substrate material from underneath the coating.

EXAMPLE

Different types of cells may be used for the organics destruction, including H-cells and flat plate cells. The anolyte and catholyte reservoirs are sealed and separated by a Nafion 117 membrane. In a single electrode mode H-cell design, one arm of the cell contains a platinum cylinder or strip anode, and a platinum strip cathode in the other arm. For a bipolar electrode mode, each arm of the H-cell would contain a complete electrochemical cell, and the cell separator is a bipolar electrode. The flat plate cell design employs a platinum anode (coated on titanium or niobium) and a cathode made from nickel, titanium, or niobium. The anolyte reservoir is equipped with a thermostated heater and nitrogen gas bubbler for efficient degassing. In a small system where the volume of the anolyte and catholyte reservoirs are one liter each, the system has a capability of up to 20 amps, with a flow rate of 0.5 gpm per cell channel. The system runs at operating temperatures of 30-60° C. The system can be scaled up for production volumes of tens or hundreds of liters.

The cobalt mediator concentration in the anolyte is at least about 0.5 M, but can be any amount that allows reasonable current densities without exceeding solubility limits. The concentration of the salt (nitrate, sulfate, phosphate) in the electrolyte can vary from 0.5 M to its solubility limit, and is typically about 2 M. The optimal concentration is the highest salt concentration that does not allow the formation of precipitates or interferring complexes. A high electrolyte concentration reduces resistance in the cell.

The organic waste is introduced into the cell in a batch mode or continuous feed mode, and the off-gas is analyzed for carbon dioxide by passage through an infrared analyzer by means of a peristaltic pump with a continuously measured gas flow rate. By integrating the volume of carbon dioxide produced over the period of a run, a rough estimate of the destruction efficiency is obtained. Samples also may be taken for Total Organic Carbon analysis before and after a run to calculate more accurate destruction efficiencies.

The foregoing description of preferred embodiments of the invention is presented for purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. 

We claim:
 1. A method for the destruction of organic waste in an electrochemical cell, comprising:providing an electrochemical cell comprising an anode, a cathode, and a separator between the anode and cathode, wherein the separator defines an anolyte reservoir containing a neutral pH anolyte solution and a catholyte reservoir containing a neutral pH catholyte solution, and wherein the anolyte solution includes a cobalt salt mediator, and the catholyte solution includes a reduceable species; introducing an organic compound into the neutral pH anolyte solution; applying a potential across the anode and cathode so as to cause Co²⁺ to be oxidized at the anode to form Co³⁺, and the reduceable species to be reduced at the cathode to form a reduced species; allowing the organic compound to react with Co³⁺ to form carbon dioxide and Co²⁺ until a desired amount of the organic compound has been destroyed; and replenishing the reduceable species in the catholyte as the reaction proceeds in the anolyte between the organic compound and Co³⁺.
 2. The method as recited in claim 1, wherein the anolyte and catholyte solutions include at least one neutral salt.
 3. The method as recited in claim 2, wherein the neutral salt is selected from nitrates, sulfates, and phosphates.
 4. The method as recited in claim 2, wherein the neutral salt is selected from salts of alkali metals.
 5. The method as recited in claim 2, wherein the neutral salt is selected from nitrates, sulfates, and phosphates of sodium and potassium.
 6. The method as recited in claim 1, wherein the reduceable species is water.
 7. The method as recited in claim 1, wherein the reduceable species is nitrate and the reduced species is nitrite.
 8. The method as recited in claim 7, wherein replenishing the reduceable species is carried out by introducing oxygen gas into the catholyte solution to react with nitrite to form nitrate.
 9. The method as recited in claim 1, wherein the concentration of cobalt mediator is greater than about 0.5 M.
 10. The method as recited in claim 1, wherein providing the electrochemical cell further comprises situating at least one bipolar electrode between the anode and the cathode, and situating a separator between each pair of electrodes, wherein the separators define a plurality of anolyte reservoirs containing anolyte solution and a plurality of catholyte reservoirs containing catholyte solution. 